Wall box mounting apparatus

ABSTRACT

An apparatus and method for mounting a device in a wall box is provided. The apparatus includes a base plate formed by a front portion and a plurality of side portions extending to the rear to define a substantially open rear portion, and a latching mechanism coupled to the base plate. The front portion is connected to the device. The base plate is configured to be at least partially inserted into the wall box. The latching mechanism includes a frictional engagement member configured to frictionally engage with the wall box upon insertion into the wall box.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of co-pending U.S. patentapplication Ser. No. 11/673,285, entitled “WALL BOX MOUNTING APPARATUS,”filed in the U.S. Patent and Trademark Office on Feb. 9, 2007, herebyincorporated by reference, having a common inventor as the presentdocument.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is related in general to the field of wall box mountings.More particularly, the invention is related to magnetic and/or frictionwall box mountings of devices.

2. Discussion of the Background

A wall box is typically mounted on a wood beam during the constructionof a home or office and is usually used to house a light switch and itsassociated wires and/or circuitry. Wall boxes today generally sufferfrom various disadvantages related to mounting. For instance, problemscan arise if the wall box is skewed in any way after it has beenmounted. In such a situation, the resulting light switch, light switchplate, or other device positioned in the wall box will appear to besimilarly skewed resulting in an unaesthetic appearance. Additionally,if the depth of the wall box mounting in the wall is too deep, thesupplied screws may be too short to affix the light switch, light switchplate, or other device to the wall box. Further, if the mounted wall boxis not parallel to the wall's surface, the mounting screws can becomecross threaded, because the screw is not received perpendicularly in areceiving nut or tapped hole, leading to eventual failure of themounting system. Problems may also arise in situations where a device,including, without limitation, an infrared receiver or an infraredplate, is positioned in a skewed manner in the wall box. For example,the performance of the device can be affected if any equipment incommunication with the device cannot adequately communicate because thedevice is not mounted properly.

Thus, as noted above, there currently exist numerous deficiencies inwall box mountings that are known in the prior art.

SUMMARY OF THE INVENTION

Accordingly, one aspect of the present invention is to provide anapparatus for mounting a device in a wall box that includes a base plateformed by a front portion and a plurality of side portions extending tothe rear to define a substantially open rear portion, and a latchingmechanism coupled to the base plate. The front portion is connected tothe device. The base plate is configured to be at least partiallyinserted into the wall box. The latching mechanism includes a frictionalengagement member configured to frictionally engage with the wall boxupon insertion into the wall box.

Another aspect of the present invention is to provide an apparatus formounting a device in a wall box that includes a base plate formed by afront portion and a plurality of side portions extending to the rear todefine a substantially open rear portion, and a latching mechanismcoupled to the device. The front portion is connected to a device. Thebase plate is configured to be at least partially inserted into the wallbox. The latching mechanism includes a frictional engagement memberconfigured to frictionally engage with the wall box upon insertion intothe wall box.

Yet another aspect of the present invention is to provide method formounting a device in a wall box that includes connecting a base plate tothe device, and coupling a latching mechanism to the base plate byfrictional engagement. The base plate is formed by a front portion and aplurality of side portions extending to the rear to define asubstantially open rear portion. The front portion is connected to thedevice. The base plate is configured to be at least partially insertedinto a wall box. The latching mechanism includes a frictional engagementmember configured to frictionally engage with the wall box uponinsertion into the wall box.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present invention and many of theattendant advantages thereof will be readily obtained as the samebecomes better understood by reference to the following detaileddescription when considered in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a front view of a base plate according to an embodiment of thepresent invention;

FIG. 2 is a rear view of the base plate according to an embodiment ofthe present invention;

FIG. 3 is an exploded rear view of the base plate coupled to a deviceaccording to an embodiment of the present invention;

FIG. 4 is a rear view of the base plate according to an embodiment ofthe present invention;

FIG. 5 is a side view of the base plate coupled to the device accordingto an embodiment of the present invention;

FIG. 6 is a top view of the base plate coupled to a device partiallyinserted into a magnetically engageable wall box according to anembodiment of the present invention;

FIG. 7 is a side view of the base plate coupled to the device accordingto an alternate embodiment of the present invention;

FIG. 8 is a side view of the base plate coupled to the device accordingto an alternate embodiment of the present invention;

FIG. 9 is a rear view of the base plate according to an alternateembodiment of the present invention;

FIG. 10 is a cutaway section of the base plate according to anembodiment of the present invention;

FIG. 11 is an exploded view of the cutaway section shown in FIG. 10according to an embodiment of the present invention;

FIG. 12 is a top view of a latching mechanism coupled to a devicepartially inserted into a wall box according to an alternate embodimentof the present invention;

FIG. 13 is a side view of the latching mechanism according to analternate embodiment of the present invention;

FIG. 14 is a rear view of the base plate according to an alternateembodiment of the present invention; and

FIG. 15 is an exploded view of the cutaway section shown in FIG. 10according to an alternate embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, preferredembodiments of the present invention are described.

Referring now to FIG. 1, a front view of a base plate 10 according to anembodiment of the present invention is shown. The base plate 10generally has a rectangular configuration defined by a front portion 14and side portions 16 (16 a, 16 b, 16 c and 16 d) extending to the rearto define a substantially open rear portion 12. The front portion 14extends along a center axis (A). The front portion 14 is operablyconfigured to be coupled to a device 28, and secured within amagnetically engageable wall box 40 by, at least in part, means of amagnetic force between the base plate 10 and the magnetically engageablewall box 40. The coupling between the front portion 14 and the device 28may be by any means known in the art, including, without limitation, ascrew, a bolt, a pin, a clip, an adhesive, a solder, or the like. Forexample, the front portion 14 may be fixedly mounted to the device 28via screws (not shown) protruding through one or more screw holes 27.Alternatively, one or more components of the base plate 10 may be formedas a portion of the device 28 itself. Additionally, more than one device28 may be coupled to one or more base plates 10 which may be operablysecured within the magnetically engageable wall box 40.

The front portion 14, the side portions 16 and the rear portion 12 maybe configured as separate components, or any combination thereof may beformed as portions of a unitary body. Side portions 16 may also includeone or more openings 20, such as holes or perforations, operable toaccommodate tie-wraps or other objects to assist in securing wires,cables, or other elements attached to or positioned near a device 28.Obviously, side portions 16 may include any number of openings 20without departing from the scope of the present invention. It is also tobe understood that the present invention is not limited to the aboveidentified connecting components and that other connecting componentsmay be used within the scope of the present invention. Each of the baseplate 10 components may be made from any material, including, withoutlimitation, metal, plastic, composite materials, or the like. In oneconfiguration, the components of the base plate 10 are made from metalfrom pressure casting or stamping.

One or more magnets 18 may be coupled to one or more of the sideportions 16. Such coupling between each magnet 18 and its respectiveside portion 16 may be fixed or displaceable. The fixed coupling may beby any means known in art, including, without limitation, a screw, abolt, a pin, a clip, an adhesive, a solder, or the like. Thedisplaceable coupling may be by any means known in art, including,without limitation, a pin, a retractor, a spring, a hinge, a livinghinge, a rivet, a screw, a bolt, or any combination thereof, or thelike. Such displaceable coupling may also be by means of an elasticallydeflectable portion of the side portions 16.

In one arrangement, as shown in FIGS. 2, 10 and 11, each magnet 18 isadjustably coupled to its respective side portion 16 by a retractor pin22 inserted through openings 23 in the side portion 16. The adjustablecoupling may also include a spring 32 connected to the retractor pin 22and configured to provide retractable resistance thereto, such that eachmagnet 18 is at least initially retracted towards its respective sideportion 16. However, it is to be understood that a spring is notrequired within the scope of the present invention. In an alternatearrangement, as shown in FIGS. 14 and 15, each magnet 18 is fixedlycoupled to its respective elastically deflectable side portion 16 by ascrew, bolt or the like inserted through openings 23 in the elasticallydeflectable side portion 16.

As shown in FIG. 4, the side portions 16 may also include recesses 19that are larger than the diameter of the magnets 18, such that at leasta portion of each magnet 18 may be retracted interior to the outersurface of its respective side portion 16. As shown in FIGS. 1-6, themagnets 18 may be adjustably coupled to side portions 16 a and 16 b,operatively allowing movement in a direction (B) that is transverse tothe center axis (A), such that the magnets move in an outward directionaway from the base plate 10 and towards a magnetically engageable wallbox 40. Alternatively, as shown in FIG. 7, the magnets 18 may also beadjustably coupled to side portions 16 c and 16 d, operatively allowingmovement in a direction along the center axis (A). It is to beunderstood that any number of magnets 18 may be coupled to any one ormore of the side walls 16, the front portion 14, the rear portion 12, orany combination thereof within the scope of the present invention.Thereby, a device 28 coupled to the base plate 10 may be easily alignedand/or adjusted in a proper orientation with respect to the magneticallyengageable wall box 40 and the wall.

The front portion 14 and/or one or more of the side portions 16 mayinclude a cut-out portion 24 operable to accommodate elements attachedto or positioned near the device, to assist in the dissipation of heatfrom the device 28 and/or to accommodate wires or other cabling.However, it is to be understood that the front portion 14 and/or one ormore of the side portions 16 may also be configured without cut-outportion 24, as shown in FIG. 9.

Although shown in FIG. 1 as having a rectangular shape, the base plate10 may also be arranged in a variety of shapes, including, withoutlimitation, a square, a rectangular, a octagonal, an oval, and acircular shape, or the like within the scope of the invention. Likewise,the cut-out portion may be arranged in a variety of shapes. The baseplate 10 and the cut-out portion 24 may also be arranged in a variety ofthicknesses and sizes. Additionally, any number of magnets 18 of variousshapes, thicknesses, and sizes may be arranged on any portion of thebase plate 10 in various locations without departing from the scope ofthe present invention. For example, as shown in FIGS. 7 and 8, themagnets may be arranged, respectively, on the rear portion 12 or any ofthe side portions 16. Alternatively, one or more of the magnets 18 maybe replaced with magnetized portions of the base plate 10 itself. Forinstance, one or more of the side portions 16 may be magnetized. In thisconfiguration, the side portions 16 may be operatively configured to beadjustable in an outward direction (A and/or B) away from the base plate10 and towards a magnetically engageable wall box 40. In one possiblearrangement, the side portions 16 are adjustably coupled to the frontportion 14 using any means known in the art. In another configuration,the rear portion 12 is magnetized. In this configuration, the rearportion 12 may be operatively configured to be adjustable in a direction(C) that is longitudinal to the center axis (A), such that the rearportion 12 is adjustable in an outward direction (C) away from the baseplate 10 and towards a magnetically engageable wall box 40. The rearportion 12 may be adjustably coupled to the side portions 16 using anymeans known in the art.

Referring now to FIG. 2, a rear view of the base plate 10 according toan embodiment of the present invention is shown. As shown at cutawaysection 26 in FIG. 2, and, in particular, FIG. 10, side portions 16 cand 16 d may be extended to overlap neighboring side portions 16 a and16 b. Obviously, other overlap configurations are possible withoutdeparting from the scope of the present invention. Such overlap, asshown in cutaway section 26, may operably be provided such thatretractors 22 are more securely coupled to the side portions 16.

As previously discussed, one or more of the side portions 16 may be aunitary extension of the front portion 14 formed to the shape shown inFIG. 2 by any means known in the art, including, without limitation,molding, pressure casting, stamping, or the like. For example, FIG. 9depicts one possible alternate arrangement in which the side portions 16are a unitary extension of the front portion 14.

Referring now to FIG. 4, a side view of the base plate 10 coupled to adevice 28 according to an embodiment of the present invention is shown.The device 28 may or may not be configured to be coupled to a switchplate 30 facing or the like. In one possible configuration, the device28 houses a circuit (not shown) that operably provides a communicationfunctionality, including, without limitation, transferring audio orvideo signals, operating a light source, operating a thermostat, oroperating other types of devices. In another configuration, the device28 itself is the circuit. The device may also be coupled to, withoutlimitation, a switch plate, a light switch, an infrared receiver, aninfrared transmitter, an audio control, a light source, a thermostat, avideo control, a multi-media control, a wireless transmitter, anelectronic device or the like. The base plate 10 and the device 28 maybe further configured to be secured within a magnetic wall box 40, suchthat the base plate 10 and the device 28 (and including any attachedswitch plate facing or other coupling) is flush with the wall surface.

Referring now to FIG. 4, a side view of the base plate 10 coupled to thedevice 28 according to an embodiment of the present invention is shown.Obviously, the overall dimensions of the base plate 10 and the device28, including, without limitation, the size, shape, and thicknessthereof, may be altered within the scope of the present invention aslong as the base plate 10 and the device 28 are able to fit within themagnetically engageable wall box 40.

Referring to FIGS. 3 and 5, an exploded rear view and top view,respectively, of the base plate 10 coupled to a device 28 according toan embodiment of the present invention are shown. FIG. 6 further showsthe base plate 10 and the device 28 partially inserted into amagnetically engageable wall box 40 according to an embodiment of thepresent invention. As the base plate 10 is inserted, the magnets 18engage the inside walls of the magnetically engageable wall box 40. Nomounting screws are required to properly position the switch plate 30 inrelation to a wall even if the magnetically engageable wall box 40 isnot properly mounted. The magnetic force exerted by the magnets 18 isconfigured such that the base plate 10 and the coupled device 28 (andincluding any attached switch plate, facing, or other coupling) may beadjusted after insertion into the magnetically engageable wall box 40.Further, the magnetic force exerted by the magnets 18 and/or frictionalengagement may be configured such that it prevents small children fromremoving the switch plate 30. Alternatively, at least a portion of theinterior of the magnetically engageable wall box 40 is magnetizedinstead of, or in combination with, the magnets 18.

In one embodiment, a base plate 10 includes at least one magnet 18 andat least one spring 32 coupled to the magnet 18. The magnet 18 isconfigured to allow movement in an outward direction (A, B or C) awayfrom the base plate 10 when the base plate 10 is placed in amagnetically engageable wall box 40. The base plate 10 movesproportionally to a tension of the spring 32. The base plate 10 iscoupled to a device 28, such as a circuit, to provide variousfunctionality. The functionality may include, without limitation,receiving audio signals, processing audio signals, transferring audiosignals, receiving video signals, processing video signals, transferringvideo signals, operating a light source, operating a thermostat,operating an electronic device and operating a mechanical device. Thedevice 28 of the base plate 10 may be coupled to a switch plate operableto control the device 28. The magnets 18 are operable to align thedevice 28 in the magnetically engageable wall box 40, and to align theswitch plate in proximity to the magnetically engageable wall box 40.The base plate 10 may also include a cut-out portion.

Referring now to FIG. 12, a top view of a latching mechanism 50 coupledto a device 28 partially inserted into a wall box 54 according to analternate embodiment of the present invention is shown. The latchingmechanism 50 includes one or more ridge 60 (or tooth) operativelyconfigured upon insertion to detachably engage one or more correspondingridge 56 (or tooth) on at least one interior surface of the wall box 54.In one configuration, the latching mechanism 50 is coupled to anexterior surface of the device 28. Alternatively, the latching mechanism50 may be coupled to an exterior surface of the base plate 10. When thedevice 28 is inserted into the wall box 54, the latching mechanism 50elastically deflects in a direction (A) toward the device 28, and theridge 60 of the latching mechanism 50 catches and rests against a ridge56 of the interior surface of the wall box 54. As such, the device 28 isfirmly positioned within the wall box 54. If the device 28 is to beremoved from the wall box 54, or repositioned within the wall box 54,the latching mechanism 50 may be depressed in a direction (A), such thatthe ridge 60 from the mechanism 50 releases an engaged ridge 56. Thelatching mechanism 50 may move back and forth in a direction (A) suchthat the latching mechanism 50 is retracted when being placed in thewall box 54 or refracted when being removed from the wall box 54.Obviously, the number, sizes, shapes and locations of the latchingmechanism 50 or the ridges 56 may differ without departing from thescope of the present invention. Also, the wall box 54 may be of varioussizes and shapes and may be magnetized or non-magnetized within thescope of the present invention. For example, as shown in FIG. 12, thebase plate 10 includes the magnets 18 and is connected to the device 28such that base plate 10 and the device 28 are secured in the wall box 54by both magnetic and frictional engagement. The magnetic engagementoperates as discussed above with respect to FIGS. 1-11.

Referring now to FIG. 13, a side view of the latching mechanism 50according to an alternate embodiment of the present invention is shown.In this configuration, the device 28 is secured to a wall box 54 bymeans of frictional engagement Specifically, when the device 28 isinserted into the wall box 54, at least one ridge 60 (or tooth) catchesand rests against one of a series of ridges 56 (or teeth) on an interiorportion 62 of the wall box 54. Obviously, the number, sizes, shapes andlocations of the ridge or tooth 60 can differ within the scope of thepresent invention. Further, an alternate object, such as one that ismore bulbous, may be used instead of the ridge or tooth 60 and may beplaced in a slot attached to, or a part of, the interior portion 62(instead of the series of ridges or teeth 56).

Although an exemplary embodiment of the system of the present inventionhas been illustrated in the accompanied drawings and described in theforegoing detailed description, it will be understood that the inventionis not limited to the embodiments disclosed, but is capable of numerousrearrangements, modifications, and substitutions without departing fromthe spirit of the invention as set forth and defined by the followingclaims. For example, the capabilities of the invention can be performedfully and/or partially by a single component or multiple components.Also, these capabilities may be performed in the current manner or in adistributed manner and on any device able to provide and/or receiveinformation. Further, although depicted in a particular manner, variousmodules or blocks may be repositioned without departing from the scopeof the present invention. For example, the device 28 and/or the switchplate 30 may include magnets or be magnetized. Still further, althoughdepicted in a particular manner, any number of modules and connectionscan be utilized with the present invention in order to accomplish thepresent invention, to provide additional known features to the presentinvention and/or to make the present invention more efficient. Forexample, in situations where a non-magnetic wall box is used, springsmay be manually adjusted to ensure that when one or more magnets areplaced the non-magnetic wall box, the force exerted by the magnetsagainst a non-magnetic surface of the wall box is sufficient to hold thebase plate 10, the device 28, and the switch plate 30, securely in placewithin the wall box. Also, information sent between various modules(including the device 28 and the switch plate 30), may be transmittedbetween the modules via a wireless source, a wired source and/or aplurality of protocols.

Obviously, many other modifications and variations of the presentinvention are possible in light of the above teachings. The specificembodiments discussed herein are merely illustrative, and are not meantto limit the scope of the present invention in any manner. It istherefore to be understood that within the scope of the disclosedconcept, the invention may be practiced otherwise than as specificallydescribed.

1. An apparatus for mounting a device in a wall box, comprising: a baseplate formed by a front portion and a plurality of side portionsextending to the rear to define a substantially open rear portion,wherein the front portion is connected to the device, and wherein thebase plate is configured to be at least partially inserted into the wallbox; and a latching mechanism coupled to the base plate, wherein thelatching mechanism includes a frictional engagement member configured tofrictionally engage with the wall box upon insertion into the wall box.2. The apparatus of claim 1, wherein the latching mechanism includes oneor more ridges that elastically deflect to catch and rest againstcorresponding one or more ridges of the wall box upon insertion into thewall box.
 3. The apparatus of claim 1, wherein the latching mechanism isconfigured to engage and disengage with the wall box by elasticdeflection of the latching mechanism.
 4. The apparatus claim 1, whereinthe latching mechanism is coupled to an exterior surface of the baseplate.
 5. The apparatus claim 1, further comprising at least one magnet,each of the at least one magnet being connected to an interior wall ofthe wall box, wherein the at least one magnet is operably configured tomagnetically engage the base plate.
 6. The apparatus of claim 5, whereinthe base plate includes a plurality of side walls, and wherein at leastone of the plurality of side portions comprises an elasticallydeflectable portion configured to permit the at least one of theplurality of side portions to move in an outward direction relative toone of the plurality of side walls when the at least one magnet engagesthe base plate.
 7. The apparatus of claim 1, further comprising at leastone magnet, each of the at least one magnet being connected to the baseplate, wherein the at least one magnet is operably configured tomagnetically engage the wall box.
 8. The apparatus of claim 7, whereinthe base plate includes a plurality of side walls, and wherein at leastone of the plurality of side portions comprises an elasticallydeflectable portion configured to permit the at least one of theplurality of side portions to move in an outward direction relative toone of the plurality of side walls when the at least one magnet engagesthe wall box.
 9. The apparatus of claim 1, wherein the latchingmechanism includes one or more bulbous portions that catch and restagainst corresponding slots of the wall box upon insertion into the wallbox.
 10. An apparatus for mounting a device in a wall box, comprising: abase plate formed by a front portion and a plurality of side portionsextending to the rear to define a substantially open rear portion,wherein the front portion is connected to a device, and wherein the baseplate is configured to be at least partially inserted into the wall box;and a latching mechanism coupled to the device, wherein the latchingmechanism includes a frictional engagement member configured tofrictionally engage with the wall box upon insertion into the wall box.11. The apparatus of claim 10, wherein the latching mechanism includesone or more ridges that elastically deflect to catch and rest againstcorresponding one or more ridges of the wall box upon insertion into thewall box.
 12. The apparatus of claim 10, wherein the latching mechanismis configured to engage and disengage with the wall box by elasticdeflection of the latching mechanism.
 13. The apparatus of claim 10,wherein the latching mechanism is coupled to an exterior surface of thedevice.
 14. The apparatus of claim 10, further comprising at least onemagnet, each of the at least one magnet being connected to an interiorwall of the wall box, wherein the at least one magnet is operablyconfigured to magnetically engage the base plate.
 15. The apparatus ofclaim 14, wherein the base plate includes a plurality of side walls, andwherein at least one of the plurality of side portions comprises anelastically deflectable portion configured to permit the at least one ofthe plurality of side portions to move in an outward direction relativeto one of the plurality of side walls when the at least one magnetengages the base plate.
 16. The apparatus of claim 10, furthercomprising at least one magnet, each of the at least one magnet beingconnected to the base plate, wherein the at least one magnet is operablyconfigured to magnetically engage the wall box.
 17. The apparatus ofclaim 16, wherein the base plate includes a plurality of side walls, andwherein at least one of the plurality of side portions comprises anelastically deflectable portion configured to permit the at least one ofthe plurality of side portions to move in an outward direction relativeto one of the plurality of side walls when the at least one magnetengages the wall box.
 18. The apparatus of claim 10, wherein thelatching mechanism includes one or more bulbous portions that catch andrest against corresponding slots of the wall box upon insertion into thewall box.
 19. A method for mounting a device in a wall box, comprising:connecting a base plate to the device, the base plate being formed by afront portion and a plurality of side portions extending to the rear todefine a substantially open rear portion, wherein the front portion isconnected to the device, and wherein the base plate is configured to beat least partially inserted into a wall box; and coupling a latchingmechanism to the base plate by frictional engagement, wherein thelatching mechanism includes a frictional engagement member configured tofrictionally engage with the wall box upon insertion into the wall box.20. The method of claim 19, further comprising magnetically engaging thebase plate using at least one magnet connected to an interior wall ofthe wall box.